Previous ed.: Upper Saddle River, N.J.: Prentice-Hall; London

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Chapter 1 INTRODUCTION 1 1.1 Production Systems 3 1.2 Automation in Production Systems 9 1.3 Manual Labor in Production Systems 13 1.4 Automation Principles and Strategies 15 1.5 Organization of this Book 20 PART I: OVERVIEW OF MANUFACTURING 23 Chapter 2 MANUFACTURING OPERATIONS 23 2.1 Manufacturing Industries and Products 27 2.2 Manufacturing Operations 30 2.3 Production Facilities 34 2.4 Product/Production Relationships 39 2.5 Lean Production 44 Chapter 3 MANUFACTURING MODELS AND METRICS 48 3.1 Mathematical Models of Production Performance 49 3.2 Manufacturing Costs 57 APPENDIX Averaging Procedures for Production Models 66 PART II: AUTOMATION AND CONTROL TECHNOLOGIES 69 Chapter 4 INTRODUCTION TO AUTOMATION 69 4.1 Basic Elements of an Automated System 71 4.2 Advanced Automation Functions 79 4.3 Levels of Automation 84 Chapter 5 INDUSTRIAL CONTROL SYSTEMS 88 5.1 Process Industries Versus Discrete Manufacturing Industries 89 5.2 Continuous Versus Discrete Control 91 5.3 Computer Process Control 97 Chapter 6 HARDWARE COMPONENTS FOR AUTOMATION AND PROCESS CONTROL 114 6.1 Sensors 115 6.2 Actuators 119 6.3 Analog-to-Digital Converters 128 6.4 Digital-to-Analog Converters 131 6.5 Input/Output Devices for Discrete Data 134 Chapter 7 NUMERICAL CONTROL 139 7.1 Fundamentals of NC Technology 142 7.2 Computer Numerical Control 148 7.3 Distributed Numerical Control 153 7.4 Applications of NC 156 7.5 Engineering Analysis of NC Positioning Systems 163 7.6 NC Part Programming 171 Appendix A 7: Coding for Manual Part Programming 189 Appendix B 7: Part Programming with Apt 197 Chapter 8 INDUSTRIAL ROBOTICS 213 8.1 Robot Anatomy and Related Attributes 215 8.2 Robot Control Systems 221 8.3 End Effectors 223 8.4 Sensors in Robotics 224 8.5 Industrial Robot Applications 225 8.6 Robot Programming 233 8.7 Robot Accuracy and Repeatability 241 Chapter 9 DISCRETE CONTROL USING PROGRAMMABLE LOGIC CONTROLLERS AND PERSONAL COMPUTERS 250 9.1 Discrete Process Control 250 9.2 Ladder Logic Diagrams 258 9.3 Programmable Logic Controllers 262 9.4 Personal Computers Using Soft Logic 269 PART III: MATERIAL HANDLING AND IDENTIFICATION TECHNOLOGIES 273 Chapter 10 MATERIAL TRANSPORT SYSTEMS 273 10.1 Introduction to Material Handling 274 10.2 Material Transport Equipment 279 10.3 Analysis of Material Transport Systems 296 Chapter 11 STORAGE SYSTEMS 313 11.1 Storage System Performance and Location Strategies 314 11.2 Conventional Storage Methods and Equipment 318 11.3 Automated Storage Systems 321 11.4 Engineering Analysis of Storage Systems 329 Chapter 12 AUTOMATIC IDENTIFICATION AND DATA CAPTURE 342 12.1 Overview of Automatic Identification Methods 343 12.2 Bar Code Technology 346 12.3 Radio Frequency Identification 354 12.4 Other AIDC Technologies 356 PART IV: MANUFACTURING SYSTEMS 359 Chapter 13 INTRODUCTION TO MANUFACTURING SYSTEMS 359 13.1 Components of a Manufacturing System 361 13.2 A Classification Scheme for Manufacturing Systems 366 13.3 Overview of the Classification Scheme 373 Chapter 14 SINGLE-STATION MANUFACTURING CELLS 378 14.1 Single-Station Manned Cells 379 14.2 Single-Station Automated Cells 380 14.3 Applications of Single-Station Cells 385 14.4 Analysis of Single-Station Systems 390 Chapter 15 MANUAL ASSEMBLY LINES 401 15.1 Fundamentals of Manual Assembly Lines 403 15.2 Analysis of Single Model Assembly Lines 410 15.3 Line Balancing Algorithms 417 15.4 Mixed Model Assembly Lines 422 15.5 Workstation Considerations 434 15.6 Other Considerations in Assembly Line Design 435 15.7 Alternative Assembly Systems 438 Chapter 16 AUTOMATED PRODUCTION LINES 448 16.1 Fundamentals of Automated Production Lines 449 16.2 Applications of Automated Production Lines 458 16.3 Analysis of Transfer Lines 462 Chapter 17 AUTOMATED ASSEMBLY SYSTEMS 481 17.1 Fundamentals of Automated Assembly Systems 482 17.2 Quantitative Analysis of Assembly Systems 488 Chapter 18 CELLULAR MANUFACTURING 507 18.1 Part Families 509 18.2 Parts Classification and Coding 512 18.3 Production Flow Analysis 516 18.4 Cellular Manufacturing 518 18.5 Applications of Group Technology 523 18.6 Quantitative Analysis in Cellular Manufacturing 525 Chapter 19 FLEXIBLE MANUFACTURING SYSTEMS 538 19.1 What is a Flexible Manufacturing System? 540 19.2 FMS Components 545 19.3 FMS Applications and Benefits 555 19.4 FMS Planning and Implementation Issues 558 19.5 Quantitative Analysis of Flexible Manufacturing Systems 560 PART V: QUALITY CONTROL IN MANUFACTURING SYSTEMS 585 Chapter 20 QUALITY PROGRAMS FOR MANUFACTURING 585 20.1 Quality in Design and Manufacturing 586 20.2 Traditional and Modern Quality Control 587 20.3 Process Variability and Process Capability 590 20.4 Statistical Process Control 594 20.5 Six Sigma 605 20.6 The Six Sigma DMAIC Procedure 608 20.7 Taguchi Methods in Quality Engineering 615 20.8 ISO 9000 620 Chapter 21 INSPECTION PRINCIPLES AND PRACTICES 629 21.1 Inspection Fundamentals 630 21.2 Sampling vs. 100% Inspection 635 21.3 Automated Inspection 639 21.4 When and Where to Inspect 641 21.5 Quantitative Analysis of Inspection 645 Chapter 22 INSPECTION TECHNOLOGIES 658 22.1 Inspection Metrology 659 22.2 Contact vs.

Noncontact Inspection Techniques 663 22.3 Conventional Measuring and Gaging Techniques 664 22.4 Coordinate Measuring Machines 665 22.5 Surface Measurement 679 22.6 Machine Vision 682 22.7 Other Optical Inspection Methods 688 22.8 Noncontact Nonoptical Inspection Techniques 691 PART VI: MANUFACTURING SUPPORT SYSTEMS 697 Chapter 23 PRODUCT DESIGN AND CAD/CAM IN THE PRODUCTION SYSTEM 697 23.1 Product Design and CAD 699 23.2 CAD System Hardware 705 23.3 CAM, CAD/CAM, and CIM 708 23.4 Quality Function Deployment 712 Chapter 24 PROCESS PLANNING AND CONCURRENT ENGINEERING 719 24.1 Process Planning 720 24.2 Computer-Aided Process Planning 726 24.3 Concurrent Engineering and Design for Manufacturing 728 24.4 Advanced Manufacturing Planning 732 Chapter 25 PRODUCTION PLANNING AND CONTROL SYSTEMS 737 25.1 Aggregate Production Planning and the Master Production Schedule 740 25.2 Material Requirements Planning 741 25.3 Capacity Planning 747 25.4 Shop Floor Control 749 25.5 Inventory Control 755 25.6 Extensions of MRP 762 Chapter 26 JUST-IN-TIME AND LEAN PRODUCTION 769 26.1 Lean Production and Waste in Manufacturing 770 26.2 Just-in-Time Production Systems 774 26.3 Autonomation 781 26.4 Worker Involvement 785